Building unit



3 Sheets-Sheet l :are

ATTORNEYS.

Nov. 3, 1936. A. RElslG BUILDING UNIT Filed Jan. 2, 195e I5 Sheets-Sheerl 2 .FTE IZ //2 'i /L/z's F73 ZZ HG Z3 me ATTORNEYS.

Y /22 wwf NOV. 3, 1936. A. RESIS` 2,059,490

BUILDING UNIT Filed Jan. 2, 1936 3 Sheets-Sheet 3 a 220 ma l INVENTOR. ITIS 2 7 22'/ M70/METTE RE/s/G,

fr/ l A A TTORNEYS.

Patented Nov. 3, 1936 UNITED STATES PATENT OFFICE 2,059,490 A UnmNc. nm'r Antoinette Reisig, Fords, N. li.

2 Claims.

In thepresent invention, there is presented an improved form of a building unit which may be used as a veneering for walls of buildings where` ing instrumentalities other than the cement layer in which the respective individual units of the improved construction are embedded.

More specifically, the invention comprises a building unit of the above indicated character which is produced in large slabs, and which may be applied in such large slabs to the wall founday tion by embedding the slabs'in the cement layer.

The material of these slabs may be ofy various materials of an asphaltic nature, or it may be of an asbestos composition, or the like, the surface of which may be finished on one side in one manner, as by theapplication of a granular or mineral-like dressing, with a different type of finish on the reverse side so as to enable the production of different effects to the wall depending upon which side of the slab is placed outwardly. At' least one of the slab surfaces may be divided into suitable designs, by impressing or printing upon the base suitable markings, ysuch as'grooves, lines, or the like, which markings are finished in colors contrasting with the general color of the slab. These markings enable the slab to resemble brick of the standard type with the contrasting colors simulating mortar lines, or many other varieties of designs may be employed.

One of the features of the improved unit lies in the application of breakage or cleavage lines to the body of the slab, whereby individual small units may be readily broken from the large slab as desired, as when areas smaller than the area of one of the large slabs is to be covered. In this way, a high degree of exibility may be obtained in the application and adaptation of the unit to any desired Wall space.

Aiurther feature of the invention lies in the Application January 2, 193s, sensi No. 57,204

(Cl. 'Z2-18) upon the material comprising the body of the slab.

' That is to say, if the slab is composed of some hard material such as a pressed asbestosl composition, for example, the lines may be applied by a printing'roll or the like, carrying the contrasting color- 5 ing to simulate mortar lines, and the breakage lines may be applied by a cutter such as a rotary saw positioned preferably in advance of the printing rolls; or if the simulated mortar lines be produced in other ways, as for example by cutting a` I groove in the pressed composition of the slab, rotary milling cutters may be employed for cutting these grooves, which may then be iilled with some material of a color contrasting to the color of the body of the slab. Such material may be a granulated m-ineral substance which has been suitably colored; or if the slab itself is made of some relatively soft material, such as an asphaltic composition, the breakage lines may be applied by providing the roll with a cutting edge, and also with longitudinally extending ribs `or the like to .press the aforesaid grooves into the body of the slab, as will be described in detail hereinafter.

Further objects and advantages of the invention will becomev apparent as the' description proceeds, 25V

and the features of novelty will be set forth speciflcally in the appended claims. The invention. accordingly comprises the several steps and the relation and orderk of one or more of such steps with respect to each of the others, and the product possessing the features which are exemplied in the following detailed disclosure, and the scope of the application of which will be indicated in the claims.

From the foregoing it will be apparent that the present invention provides a building unit which is in the nature of an imitation of unglazed brick or tile preferably in nexible or plastic sheets provided with .division lines which enable the sheet to be divided into smaller portions defining one or more individual units. v

The invention will be more readily understood by reference to the accompanying drawings,v which are illustrative of certain features of the invention, and in which Fig. 1 represents a fragmentary perspective view of a wall construction embodying the, improved building unit of the present invention, the

unit being shown as applied to a stucco foun-y dation, g 50 Fig. 2 is. a similar view to Fig. 1, but illustrates one way of applying the improvedv unit to the usual weather-boarding of a wall of frame con struction, Y, v Fig. 3 represents a portion of, one form of the present improved unit, showing one form of design or pattern which may be applied to the surface of' the unit,

Fig. 4 is an enlarged fragmentary sectional elevation of the portion of the unit shown in Fig. 3,

Fig. 5 is an elevation of a modifiedform of unit, indicating a different form of pattern that may be applied thereto,

Fig. 6 is an enlarged fragmentary sectional elevation of the form of unit shown in Fig. 5,

Fig. '7 is an elevational view of the reverse side of the unit of Fig. 5, the view indicating a different style of finish L,from that presented by the surface of the unit shown in Fig. 5,

Fig. 8 is an elevational view showing a still different type of a pattern and finish which may be applied to the unit,

Fig. 9 is an enlarged fragmentary sectional elevation of the unit of Fig. 8,

Fig. 10. is an elevational view of still another form of modification,

Fig. 11 is an enlarged fragmentary sectional elevation of the form of unit shown in Fig. 10,

Fig. 12 is a view generally similar to Fig. 8, but showing the application `of fracture lines to the unit, whereby a large slab may be broken readily into smaller sizes of units as may be desired,

Fig. 13 is an enlarged fragmentary sectional elevation of the modification shown in Fig. 12,

Fig. 14 is an elevational view generally similar to the showing of Fig. 10, but showing a still further modification of the surface finish,

Fig. 15 is an enlarged fragmentary sectional elevation of the modification of Fig. 14,

Fig. 16 is an elevational view ofstill a different modification, the view illustrating the application of a desiredpattern to a unit having an asphaltic or bituminous body.

Fig. 17 is an enlarged fragmentary sectional elevation of the modification of Fig. 16, and with Fig. 16, showing a fracture line impressed in the body of the unit,

Fig. 18 is another modification of an asphaltic unit, showing a still different nish and appearance presented by the unit,

Fig. 19 is an enlarged fragmentary sectional elevation of the modification of Fig. 18,

Fig. 20 is an elevation of a further modification of a unit generally similar to Fig. 16, but produced with a difi'erent'pattern on the reverse side,

Fig. 21 is an enlarged sectional elevation of the unit of Fig. 20,

Fig. 22 is a view generally similar to Fig. 18, but showing a different type of iinish,

Fig. 23 is an enlarged sectional elevation of a fragment of the unit of Fig. 22,

Fig. 24 represents, diagrammati'cally, one' form of means for applying fracture lines and patterns to a unit having a plastic body,

Fig. 25 vis a view similar to Fig. 24, but showing a manner of operating upon a non-plastic unit to apply fracture lines and to apply, as by print- Fig. 28 is an elevation of the side of a printing and marking roller adapted for use in connection with a unit having a plastic body,

Fig. 29 is an end view of the roller of Fig. 27, the view being taken alongl the line 28-28 of Fig. 27, looking in the direction of the arrows.

As is indicated on the drawings, the unit of this invention may be made of either a plastic material, such asA an asphaltic or bituminous material, or in the form of a non-plastic base, such as a compressed asbestos fiber composition or board. The unit is formed in large sheets or slabs, which are adapted to be applied to a wall foundation by embedding the sheets or slabs individually in a layer of composition cement of suitably viscous and tacky properties, which will bond to both the foundation of the Wall and to the sheet or slab being applied to the wall,.and which will secure the sheet or slab in position during the setting period of the cement layer. No fastening instrumentalities are employed for the unit other than the bonding cement. This cement is suiiiciently plastic to be applied to the Wall foundation with a trowel or similar tool, and to be spread readily into a covering of desired uniform thickness by suitable manipulations of the tool. The slab or sheet comprising the present invention is then applied to the cement layer and pressed therein, the cement holding the sheet in place as the cement sets. It is preferable, of course, for the foundation of the wall to be flush and even, although any type of material may form the foundation, such as stucco, brick, or wood. Suitable patterns and finishes may be applied to the sheets or slabs forming the units of the presentpinvention, as will be described in more detail hereinafter, such being applied, of course, before the sheets are put in position on the wall.

In Fig. 1, the foundation 30 of the Wall is shown as being made of stucco, mortar, or the like, and it has a layer 32 of composition cement applied thereto, this cement being of the characteristics referred to above. Embedded suitably in the cement layer 32 is a sheet or slab 34. defining a unit formed in accordance with the present invention. The unit 34 of Fig. 1 is represented as being of a plastic basel such as an asphaltic or bituminous composition which is substantially non-tacky at ordinary atmospheric temperatures, but which is rather soft under working conditions, as will be brought out in greater detail hereinafter. The surface of the sheet 34 may be marked to simulate brick, or tile, or any other desired ornamental design or pattern. The sheet or slab 34 is bonded to the wall foundation 30 by the cement layer 32.

In Fig. 2, the wall foundation isrillustrated for purposes of illustration as being composed of the conventional weather-boarding 30a, to which are applied in a suitable manner the inserts 36 so that a iiush ,and even surface is presented for the application of the cement layer 32, which is the same as the layer 32 illustrated in Fig. 1. The sheet 34 is then applied to the cement layer in the same manner as in Fig. 1. In Fig. 2, the sheet 34 is illustrated as being made from a nonplastic, rigid composition, such as asbestos fiber board, for example.

It is thought that the manner of applying the sheets forming the units of the present invention will be clear from the above description and from Figs. 1 and 2.

It has been mentioned above that various designs and patterns or finishes may be applied to the sheets of the present invention, in order that varying appearances may be obtained, and such designs and finishes may differ on the reverse sides of the sheets, which are thereby rendered reversible in their application, depending on whatever the desired appearance is to be produced.

Thus, in Figs. 3 and 4, the base 36 `is shown as being provided on one sidewith strips of color 38 and 40, which have been applied to the base 36 by any suitable process, as by a printing process, the other side of the base 36 being provided with a layer '42 of suitably colored material, which coloring may be applied solidly if desired over the entire surface of the base. The lines 38 and 40 are applied so as to be of equal thickness, as shown in an exaggerated manner in Fig. 4, so as to provide a ush surface at their intersections. The base 36 is illustrated as being of a relatively soit, plastic material, such as asphalt or bitumen, which, however, is non-tacky and non-flowing under atmospheric temperatures. A method of applying the desired patterns will be indicated hereinafter.

In Figs. 56, and 7, there is illustrated a modiflcation in which a non-plastic base 44 has applied thereto on one side a solid color 46, which terminates short of the margin, the margin being finished by a strip of contrasting color 48 extending around two sides of the unit, as shown in Fig. 5. As will be seen from Figs. 6 and 7, the reverse surface of the unit may have applied thereover a colored layer 50 of granulated material, such as a mineral or slate substance impregnatedwith a desired coloring, and united with the base 44 by the application thereto of a suitable adhesive.

. A contrastingly colored border 52 also of granular mineral material is shown as extending around two sides of the unit.

Fig. 8 shows also the non-plastic base 44, one surface of which has a roughened surface and which has applied `to it colored lines 56 vof granular material, simulating roughened mortar lines, and dividing the surface of the sheet or slab into a pattern simulating brickwork, similar to the showing in Figs. 1 and 2. The yreverse side 58 of the base 44 is shown as being substantially flat and plain. In applying the lines 56, the base 44 is grooved by milling cutters, and the colored granulated material is applied to the grooves desirably in accordance with the procedure to be described hereinafter.

In the modication shown in Figs. 10 and 11, the non-plastic base 44 is provided with a roughened fibrous surface 60, which is rabbeted around adjacent edges as indicated at 62, and the rabbeted portion 62 is substantially filled. with a line 64 of contrasting color, this line extending around the rabbeted edges, and filling the cut .to substantially flush with the surface 60. The reverse side 66 is substantially plane.

In the modification shown in Figs. 12 and 13, the base 44 is provided on one side with a granular background 68, which is marked into a suitable pattern by substantially smooth lines 10 which simulate mortar lines and divide the surface of the slab into a pattern generally simulating brick work. As shown in Fig. 12, the unit is provided with breakage lines or cuts 12, which extend into the base 44 of the unit suilciently deeply to enable the sheet or slab 0f the unit to also be provided with any desired pattern or finish.

In Figs. 14 to 15, one side of the base 45 is shown as being covered with colored granular material 16, a marginal border '|8 of granular material of a contrasting color being applied along adjacenteedges. The reverse side is shown as being substantially smooth, but it may be colored as desired, so that the sheet may be reversed and applied to the wall with either side out.

In the modification of Figs. 16 and 17, the relatively soft, pliable base 36 is shown as having grooves 80 impressed therein, thereby defining a pattern as indicated by Fig. 16. Granular material 82 is applied to both the grooves 80 and the intervening areas forming the background of the unit. The granular material in the grooves may be of a colorcontrasting with the color of the background areas. 84 of the unit is shown as being plane, but of course it may be finished in any desired manner, as has been described previously.

In Figs. 18 and 19, the plastic base 3 6 is shown as being rabbeted along adjacent edges, granular material being applied to the surface of the base and also to the rabbeted portion. The border material may be preferably of a contrasting color with respect to that used on the remaining portions of the surface; and as before, any desired design may be applied to the reverse surface 88, which is plane, however. It will be observed in Figs. 16 to 19 that the unit is provided with rabbeted edges on one side, the other side being plane, so that when the sheet or slab is applied to a wall with the grooved and rabbeted side outwardly, it will give the appearance of a rakejointed wall, while if applied with the plane surface outwardly, it gives the appearance of a flush wall. Suitable fracture lines, one of which is indicated at may be cut or impressedin the VYbase 36 as desired.-

In Figs. 20 and 21, the grooves 92 are imypressed in the relatively soft and plastic base 36 and colors 94 are applied in the grooves to simulate a rake-jointed brick wall. The reverse side is `made flush, with contrasting colors 96 and 98 applied thereto to produce the desired pattern.

Fracture lines |00 are cut or impressed in the base 36, as will be apparent, thus enabling a sheet to be broken as desired 'along predetermined lines.`

In Figs. 22 and 23, the sheet is shown as being rabbeted along adjacent edges, and the resulting rabbeted edges are provided with a colored border |02. The reverse side is shown as being plane, and covered with a granular finish I n4 the border |06 being of a contrasting color if desired;

In Figs. 24 to 27, inclusive, there are shown 'various ways of producing the units as previously described.

In Fig. 24 there is shown a sheet |08 of a relatively soft, bituminous composition and which forms a complete unit of this invention. A driving roller ||0 cooperates with a roller ||2 which revolves in the direction of the arrow H4, so as to move the sheet |08 in the direction of the arrow H6, and which impresses the pattern into the sheet |08.

Although the construction of the roller ||2 may be widely varied, a suitable construction is shown in Figs. 28 and 29, from which it will'be seen that the surface of the roller may be roughened, as indicated at H8, for imparting a corre- The reverse side l lli spondingly roughened or pebbly finish to the sheet |08. Also across the surface of the roller, there extend a plurality of ribs |22, and a circumferential rib |24, these ribs serving to impress the markings of the design into the body of the sheet |08, there resulting a design such as shown in Figs. 12 and 16, as indicated by the grooves |26 on Fig. 24.

The roller ||2 may be provided also with a sharpened circumferential edge |28, which acts as a knife edge for cutting breakage lines |09 in the sheet |08, similarly as shown in Figs. 12 and 16, for example, and the ribs |22 may be provided with cutters 234.

After passing the roller ||2, the sheet |08 passes beneath the printing roller |30, which is desirably made of rubber in view of the relative softness of the sheet |08. The roller is-provided with longitudinal ribs |32 and circumferential ribs such as indicated at |34, these ribs corresponding to the ribs of the roller ||2. The

movement of the sheet |08 rotates the roller |30 in the direction of the arrow |36.

The roller |30 engages a color-applying roller |38, this latter roller dipping into a body of color |40 contained in a container |42. The roller |38 is revolved in the direction of the arrow |44, and it becomes coated with color, transferring it to the ribs on the roller |30 by virtue of its engagement with the roller |30, the ribs on the roller |30 depositing the coloring in the grooves of the pattern impressed in the sheet |08, as indicated, for example, in Fig. 20.

A somewhat similar operation is designated by Fig. 25, which shows similar manipulations applied to a hard, non-plastic sheet |46, such as compressed asbestos fiber board, for example.

For making the breakage lines, in view of the hardness of the sheet, a toothed roller |48 is used, which is provided with saw teeth |50 for cutting the breakage lines, such as is indicated at |52. In order to form grooves in the sheet |46 such as indicated in Fig. 8, for example, the cutter |48 may be replaced by a milling cutter, or such a milling cutter may be used in conjunction with the cutter |48, in a manner which will be obvious. The sheet |46 is moved in the direction of the arrow |54 by suitable feeding mechanism, not shown, the cutter |48 being power-driven from a suitable source of power, not shown.

A printing roller |54, of a construction generally similar to the printing roller |30, of Fig. 24, is used to apply coloring. The roller |54 is made of a hard material, such as metal, in view of the hardness of the sheet |46, and it has a smooth surface. The coloring is applied to the ribs |56 by engagement thereof` with the roller |58 dipping into a body of coloring |60 held in a receptacle |62, there being produced a pattern generally similar to that shown in Fig. 8.

In Fig. 26, there is shown the application of a granular material to the background of the surface of the sheet, as indicated, for example on Fig, 12, it being understood that the sheets arc first formed in plastic condition, and subsequently setting into a hardened state.

Inaccordance with this view the plastic sheet |46, is movedy in the direction of the arrow |68 bythe rollers |10 and |12, which are driven from any suitable sourcel of power, not shown. As has been previously described, the roller lla, which is similar to roller H2 except for being smoothsurfaced, forms the breakage line |52 in the sheet |46 in a manner similar to that described in connection with Fig. 24. The roller |64 is provided with recesses |66 in the periphery of the roller, these recesses extendinglongitudinally of the roller. The roller |64 rotates in the direction of the arrow |14, and it engages a roller |16 which dips into a body of liquid adhesive material |18 which is contained in a. container |80. 'I'he contact between the roller |64 and the roller |16 rotates the latter in the direction of the arrow |82, so that the roller' 16 becomes coated uniformlly with the adhesive material |18, and transfers this material to the roller |64, whiclmroller in turn applies the adhesive to the back-ground of the sheet |46, the margins between the pattern lines being left clear of the adhesive.

Upon the surface of the sheet which has been prepared in this manner, there is distributed a granular mineral material |84, from a supply of such granular mineral material contained in a hopper |86, which hopper is provided with a cover |88 and which discharges into a funnel-shaped distributor |90 which has a discharge spout |92 extending across the sheet |46.

It will be seen that the rollers |10 and |12, cooperate not only to move the sheet through the apparatus, but also to press the mineral material |84 into the surface of the adhesive, so as to give a uniform coating of the granular material over the surface of the sheet.

It will be seen that the hopper |86 is provided with a, pipe |94 which opens adjacent to the surface of the sheet after the granular material has been applied and rolled, a suction being created through the pipe |94 by means of a suction fan, or the like, |96, which pulls air through the pipe |98 opening into the cover of the hopper |86, thereby tending to create a vacuum in the hopper |86 and thereby drawing up from the surface of the sheet any excess of the granular material which may have been deposited thereon. Such excess of granular material thus is drawn up through the pipe |94 into the hopper |86.

Obviously, if desired, suitable coloring ma.- terial may be applied to or mixed with the granular material in the hopper |86 in order to provide a desirably colored finish to the surface of the sheet.

In Fig. 2'1, there is shown a generally similar arrangement to the arrangement shown in Fig. 26, except that the parts illustrated in Fig. 27 are used to apply granular materials to the margins between the design of the pattern on the sheet, leaving the background of the sheet clear of the granular material.

In Fig. 27 the sheet |08 is represented as being of soft material of the bituminous or asphaltic composition, as has been referred to above in connection with Fig, 24. 'I'he roller 200 may be similar to the roller |30, the roller 200 engaging the roller 202 which dips into a body of adhesive 204 contained in a suitable receptacle 206. The adhesive material coats the roller 202 as the latter rotates in the direction of the arrow 208, this adhesive being applied to the circumferential ribs of the roller 200 such as is indicated, for example, by 2|0. In this manner the adhesive is applied to the spaces between the pattern which has been suitably impressed or printed on the sheet, as described above in connection with Fig. 24, a layer 2|2 of granular material being supplied from the hopper 264 and distributor 2|6, the material 2|2 being pressed into the surface of the sheet |08 and into the adhesive thereon by the action of rollers 2 I8 and 220 which revolve in the direction of the arrows 222 and 224 respectively, at least one of the rollers 2 i8 or 220 being a'power actuated roller operated from a suitable source of power. not shown. l

Excess of deposited mineral matter is drawn up through the pipe 228 by the suction fan 23|), thereby being returned to the hopper 2M.

In addition to exerting compressional force on the mineral material 2|2, the rollers 2|8 and 22|] serve to move the sheet |08 in the direction of the arrow 232.

It will be apparent, of course, that various instrumentalities may be combined with those shown in Figs. 24 to 27, inclusive, as may be desired or required to produce any desired effects as yto design and coloring as may be determined upon for any given use or adaptation of the resulting unit. l

It will be apparent, therefore, that the reversible unit of the present invention may present many different appearances or designs depending upon the finish that is given to it. Thus, the unit may be provided with colored mortar lines on both sides With a crushed lor granular slate-like material bonded to the surface; or the surface may be provided with a rough fibrous nish, suitably colored, as Where the unit is made up from a compressed asbestos composition thereby presenting at least on one surface, the roughness of the fibers comprising the body of the unit. The reverse side of the plate may be finished smoothly if desired, or it may have a rough finish produced by bonding thereto a colored granular material. Borders of contrasting colors may also be applied.

Attention has been called to the fact that the plates or slabs forming the improved unit are bonded in position by embedding the unit in a suitable adhesive, as cement 32. Such a cement which is especially suitable for the purpose is formed by mixing Portland cement with a mixture of asbestos fiber and some other brous material which will serve to feltl the asbestos ber and to provide additional body to the cement while preventing deformation of the wall struc- ,ture by preventing tendency of buckling of the embedded plates during the setting of the cement, .such felting fibrous material being cotton fibers, rock wool fibers, or the like. In practice about three parts by Weight of the total brous materials, composed of substantially equal parts of asbestos and felting bers, are mixed with approximately one part by Weight of Portland cement, and commingled with a tenacious tarry liquid such as liquid asphalt or tar in sufficient quantities to make a workable paste. The resulting cementitious material may be spread with a Vtrowel or similar tool, and when the plates are embedded therein, it will tightly bondl the plates to the foundation during the setting of the cement, and permanently uniting the plates in position.

It will be seen from the drawings, (see, for example, Figs. 12 and 20) that the breakage lines may extend in both directions of the unit. This may be accomplished by providing the roller ||2 'with cutting edges 234 on the ribs |22, which cutting edges cooperate with the circumferential cutting edge |28; and' it will be noted further that these breakage lines are applied so that when the large plates are fractured, the small divisions will be provided with Wide borders on adjacent edges, that is, along a long edge and a short edge.

What is claimed is:

1. A reversible building unit comprising a Hexible sheet adapted to be cemented to a building wall, the said sheet comprising a body having opposingfaces, one of the said faces having applied thereto areas of contrasting color to simulate a brick construction with mortar lines therebetween, the opposing face having applied thereto a pattern of a contrasting nature with respect to the simulated brick pattern, and fracture lines in the sheet enabling the sheet to be divided into smaller portions defining one or more individual units.

2. A reversible building unit consisting of a sheet comprising a body having substantially rectangular faces, grooves formed in at least one of the faces to divide the said face into areas of relief and depression, fracture lines between the areas in relief, a nish of predetermined color applied to the relief areas and a contrasting color appliedto the depressed areas, thereby forming a pattern simulating brick work with simulated mortar lines between the brick, the opposing surface of -the sheet being `substantially entirely plane, whereby the sheet when assembled with similar sheets in a wall structure with the uneven face outward presents the appearance of a brick wall having rake joints between the sheets, while when assembled with the opposite faces of the sheets outward presents the appearance of a flush-jointed wall, the said fracture lines enabling the sheet to be divided into smaller portions dening one or more individual units.

ANTOINE'I'I'E REISIG. 

